Stacked electrical connector with terminal assurance mechanism

ABSTRACT

A stacked electrical connector formed by mating an upper and a lower housing having rows of cavities containing terminals is disclosed. The upper and lower housings have primary terminal assurance provided by lances integrally formed into the housings. A secondary terminal assurance system is provided to further secure the terminals within the housings. In one embodiment, secondary terminal assurance is to terminals in the upper housing by lower housing protrusions and to terminals in the lower housing by a hinge. In another embodiment, secondary terminal assurance is provided to terminals in the upper and lower housing by upper and lower protrusions of a lock plate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a divisional of and claims priority to U.S. patentapplication Ser. No. 11/940,596 filed Nov. 15, 2007, and claims thepriority of U.S. provisional patent application No. 60/860,250 filedNov. 20, 2006, both of which are hereby incorporated by reference intheir entireties.

FIELD OF THE INVENTION

The present invention relates to electrical connectors. Morespecifically, the present invention relates to a stacked electricalconnector.

BACKGROUND OF THE INVENTION

In several different industries and for a wide variety of applications,electrical connector designs are standardized on various differentharnesses or on various different discrete ends of a particular harness.The need for standardization of electrical connectors for a particularharness design is particularly true in the automotive industry.

The electrical connectors for these harness assemblies have beenproposed having various features to afford a secure mechanical andelectrical engagement with a mating electrical connector or othermateable connecting device. In many applications, the connector includesnumerous electrical terminals or contacts. Often, these connectorsinclude housings having rows of terminal cavities. The housings arestacked together to form the connector. In some connectors, theterminals may be assembled into each housing before the housings areassembled together to build the connector. One problem with this type ofconnector is that the assembled connector must be constructed to a highdegree of precision to assure proper alignment with a mating connector.Additionally, the proper installation of each terminal within acorresponding cavity in each housing must be assured.

Therefore, there is an unmet need to provide a stacked electricalconnector with a terminal assurance mechanism that provides for aprecise loading of terminals within cavities of the each connectorhousing and that includes features assuring a precise mating of eachhousing forming the connector.

SUMMARY OF THE INVENTION

In a first exemplary embodiment of the invention, an electricalconnector is disclosed that includes an upper housing comprisingcavities configured to receive electrical terminals and upper housinglances integrally formed into the upper housing for providing primaryterminal assurance to the terminals received in the cavities in theupper housing, a lower housing configured to be mated to the upperhousing to form the electrical connector, the lower housing comprisingcavities configured to receive electrical terminals and lower housinglances integrally formed into the lower housing for providing primaryterminal assurance to terminals received in the lower housing, and asecondary terminal assurance system configured to provide secondaryterminal assurance to terminals received in the lower housing. The upperand lower lances are configured to secure terminals received in theupper and lower housings, respectively, from moving.

In one exemplary embodiment of the connector, the secondary terminalassurance system includes a hinge configured to secure terminalsreceived in the lower housing from moving when the hinge is locked intothe lower housing. The hinge is attached to the lower housing at a pivotarea that allows the hinge to partially rotate with respect to the lowerhousing about the pivot area prior to locking with into the lowerhousing. The hinge includes a hook configured to engage the terminalsreceived in the cavities of the lower housing. The hook is furtherconfigured to engage a ledge in the lower housing to lock the hinge at afixed locked position with the lower housing. The secondary terminalassurance system of this embodiment further includes wedges disposed ona top surface of the lower housing which are configured to secureterminals received in the upper housing from moving when the upper andlower housings are mated.

In a second exemplary embodiment of the connector, the secondaryterminal assurance system includes a lock plate. The lock plate includeslower protrusions configured to provide secondary terminal assurance toterminals received in the cavities of the lower housing when the lockplate is fully inserted into the lower housing. The lock plate furtherincludes upper protrusions configured to provide secondary terminalassurance to terminals received in the cavities of the upper housingwhen the upper and lower housings are mated and the lock plate is fullyinserted in the lower housing. The lock plate is detachable from thelower housing. The lock plate is configured to be partially insertedinto the lower housing to allow for terminals to be loaded into thecavities of the upper and lower housings.

In another exemplary embodiment of the invention, a method of assemblingan electrical connector is disclosed that includes providing an upperhousing comprising cavities configured to receive and secure electricalterminals and upper housing lances configured to provide primaryterminal assurance to the terminals received in the cavities in theupper housing, providing a lower housing configured to mate with theupper housing to form the electrical connector, the lower housingcomprising cavities configured to receive and secure electricalterminals and lower housing lances configured to provide primaryterminal assurance to terminals received in the lower housing, providinga secondary terminal assurance system configured to provide secondaryterminal assurance to terminals received in the upper and lowerhousings, and mating the upper and lower housings to form the electricalconnector.

In one exemplary embodiment of the method according to the invention,the secondary terminal assurance system includes a hinge configured tosecure terminals received in the lower housing from moving when thehinge is locked into the lower housing. The hinge is attached to thelower housing at a pivot area that allows the hinge to partially rotatewith respect to the lower housing about the pivot area prior to lockingwith into the lower housing, and wherein the hinge comprises a hookconfigured to engage the terminals received in the cavities of the lowerhousing. The secondary terminal assurance system further includes wedgesdisposed on a top surface of the lower housing which are configured tosecure terminals received in the upper housing from moving when theupper and lower housings are mated.

In a second exemplary embodiment of the method according to theinvention, the secondary terminal assurance system includes a lock platecomprising lower protrusions configured to provide secondary terminalassurance to terminals received in the cavities of the lower housingwhen the lock plate is fully inserted into the lower housing, and upperprotrusions configured to provide secondary terminal assurance toterminals received in the cavities of the upper housing when the upperand lower housings are mated and the lock plate is fully inserted in thelower housing. The lock plate is detachable from the lower housing.Additionally, the lock plate is configured to be partially inserted intothe lower housing to allow for terminals to be loaded into the cavitiesof the upper and lower housings.

Further aspects of the method and system are disclosed herein. Thefeatures as discussed above, as well as other features and advantages ofthe present invention will be appreciated and understood by thoseskilled in the art from the following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front perspective view of exemplary stackedelectrical connector according to a first embodiment of the invention.

FIG. 2 illustrates a rear perspective view of an exemplary stackedelectrical connector according to a first embodiment of the invention.

FIG. 3 illustrates an exploded view of the exemplary stacked electricalconnector of FIG. 1.

FIG. 4 illustrates a sectional view of the exploded view of theexemplary stacked electrical connector of FIG. 3 taken along line A-A.

FIG. 5 illustrates a sectional view of the view of the exemplary stackedelectrical connector of FIG. 3 taken along line A-A after mating.

FIG. 6 illustrates a sectional view of the exploded view of theexemplary stacked electrical connector of FIG. 3 taken along line A-Awith the terminals removed.

FIG. 7 illustrates an exploded view of an exemplary stacked electricalconnector according to a second embodiment of the invention.

FIG. 8 illustrates a front perspective view of the exemplary stackedelectrical connector of FIG. 7 after mating.

FIG. 9 illustrates a sectional view of the exploded view of theexemplary stacked electrical connector of FIG. 7 taken along line B-B.

FIG. 10 illustrates a sectional view of the exploded view of theexemplary stacked electrical connector of FIG. 9 taken along line B′-B′.

FIG. 11 illustrates the sectional view of the exemplary stackedconnector of FIG. 8 with the terminals removed and with the lock platein a pre-staged position.

FIG. 12 illustrates the sectional view of the exemplary stackedconnector of FIG. 10 with the lock plate in a pre-stated position.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which a preferred embodimentof the invention is shown. This invention may, however, be embodied inmany different forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete and will fully conveythe scope of the invention to those skilled in the art.

In an exemplary embodiment of the present invention, a stacked connector10 including a terminal assurance mechanism for securing and aligningterminals is disclosed as shown in FIG. 1. The connector 10 includes anupper housing 20 and a lower housing 30. The upper housing 20 includes arow of upper terminal cavities 21 configured to house terminals (notshown). The lower housing 30 also includes a row of lower terminalcavities 31 configured to house terminals (not shown). The connector 10has a front side 12. A rear view of connector 10 is shown in FIG. 2. Ascan be seen in FIG. 2, the connector 10 has a rear side 14.

An exploded view of connector 10 is shown in FIG. 3. As can be seen inFIG. 3, upper housing 20 includes upper tabs 22 (a similarly configuredmating tab as seen in FIG. 3 is present, but not shown, on the oppositeside of the housing 20). As can be further seen in FIG. 3, lower housing30 includes lower tabs 32. Upper housing 20 additionally includes tabrecesses 23 (a similarly configured tab recess as seen in FIG. 3 ispresent, but not shown, on the opposite side of the housing 20) forengaging corresponding lower tabs 32. Additionally, lower housingadditionally includes lower tab recesses 33 (a similarly configuredlower tab recess as seen in FIG. 3 is present, but not shown, on theopposite side of the housing 30) for engaging corresponding upper tabs22. When the upper housing 20 and the lower housing 30 are aligned andbrought into contact as shown in FIG. 1, the upper and lower tabs 22, 32engage corresponding tab recesses 33, 23 to lock the upper housing 20and lower housing 30 together to form the connector 10.

A cross sectional view of the exploded view of connector 10 from FIG. 3taken along line A-A is shown in FIG. 4. As can be seen in FIG. 4, uppercavities 21 and lower cavities 31 contain terminals 40. The terminals 40are configured to be secured within the cavities 21, 31 as shown. Inthis exemplary embodiment, the terminals 40 are clean body terminalshaving two locking points.

The primary terminal assurance is provided to the terminals 40 in theupper housing 20 by upper housing lances 24, and the primary terminalassurance is provided to the terminals 40 in the lower housing 30 bylower housing lances 34. The lances 24, 34 protrude into theirrespective cavities 21, 31 to engage their respective terminals 40behind a terminal front section 42 and prevent the terminals 40 frombeing moved towards the rear side 14 of connector 10. As can be seen inFIG. 4, the lances 24, 34 are integrally formed with their respectivehousings 20, 30. As can be further seen in FIG. 4, the leading sections42 of terminals 40 float or have minimal movement between the lances 24,34 and the upper and lower housing cavity front sections 60, 62.

As can be additionally seen in FIG. 4, a secondary terminal assurancesystem is provided that includes hinge 35. Hinge 35 provides secondaryterminal assurance for the terminals 40 located in the lower housing 30.Hinge 35 includes a hook 36 that engages terminals 40 when locked intothe lower housing 30 as shown in FIG. 4. Hinge 35 further preventsterminals 40 located in the lower housing 30 from being moved towardsthe rear side 14 of the connector 10. Hook 36 prevents the lower rearedges 44 of the terminals 40 from being withdrawn towards the rear side14 of connector 10 by engaging the edges 44 when the terminals 40 arepushed towards the rear 14 of the connector 10. Hook 36 also engages aledge 37 in the lower housing 30 to lock the hinge 35 with the lowerhousing 30. Hinge 35 further includes a pivot area 38 that allows hinge35 to partially rotate with respect to the lower housing 30 about thepivot area 38 prior to locking with or engaging the ledge 37.

As can also be seen in FIG. 4, the secondary terminal assurance systemalso includes wedges 39. The wedges 39 are disposed on a top surface 50of the lower housing 30 and are integrally formed with the lower housing30. The upper housing 20 includes secondary terminal assurance openings26 that receive the wedges 39 when the upper housing 20 and the lowerhousing 30 are mated. Wedges 39 provide secondary terminal assurance toterminals 40 located in the upper housing 20 when the upper housing 20and the lower housing 30 are mated as shown in FIG. 1. It should beunderstood that the geometry of the secondary terminal assurancemechanism need not be wedge shaped, and that other shapes that providean engaging surface to the terminals, such as blocks may be used.

A sectional view taken along line A-A of FIG. 3, after the upper andlower housings 20, 30 have been mated, is shown in FIG. 5. As can beseen in FIG. 5, secondary assurance is provided to the terminals 40located in the upper housing 20 by wedges 39. The wedges 39 prevent theterminals 40 from being withdrawn towards the rear side 14 of theconnector 10 by engaging the lower rear edges 44 of the terminals 40when the terminals 40 are pushed towards the rear side 14 of theconnector 10. Additionally, the wedges 39 prevent the terminals 40 frombeing fully inserted in the upper housing 20 if the upper and lowerhousings 20, 30 are mated prior to the terminals 40 being loaded intothe upper housing 20. Also, if a terminal 40 is not fully inserted in acavity 21, for example by being only partially inserted, a wedge 39 willimproperly contact the partially inserted terminal 40 and prevent theupper and lower housings 20, 30 from being mated. This feature providesa check of correct loading of all terminals 40 in the upper housing 20.

The loading of the terminals 40 into the top and lower housings 20, 30of connector 10 will now be explained referring to FIG. 6. FIG. 6 istaken along line A-A of FIG. 3 with terminals 40 removed and positionedto be loaded into the upper and lower housings 20, 30 from the rear side14 of the connector 10. It can be appreciated that the loading of theterminals 40 into the upper and lower housings 20, 30 may take place atdifferent times, and even at different physical locations, prior tofinal assembly of the connector 10 by mating the loaded upper and lowerhousings 20, 30.

Terminals 40 are loaded into the upper housing 20 prior to the upper andlower housings 20, 30 being mated. The terminals 40 must be fullyinserted in the upper housing 20 before the wedges 39 are received inthe opening 26 of the upper housing 20 during mating. The terminals 40are inserted into the upper cavities 21 from the rear side 14 of theconnector 10. To be fully inserted, the terminals 40 are inserted intothe cavities 21 until the front leading sections 42 of the terminalspush passed lances 24, and the lances 24 drop behind the leadingsections 42. The lances 24 are sufficiently compliant to allow the frontleading sections 42 to pass.

As can be further seen in FIG. 6, terminals 40 are loaded into the lowerhousing 30 prior to the hinge 35 being locked with the lower housing 30.If the hinge 35 is locked with the lower housing 30 prior to theterminals 40 being received in the lower housing, the hook 36 willprevent the terminals 40 from being fully received in the lower housingcavities 31. Additionally, the terminals 40 must be fully inserted inthe cavities 31 before the hinge 35 can be locked into the lower housing30. If a terminal is not fully inserted in a cavity 31, for example bybeing only partially inserted into a cavity 31, the hook 36 willimproperly contact the partially received terminal 40 and prevent thehinge 35 from locking into the lower housing 30. This feature provides acheck of correct loading of all terminals 40 in the lower housing 30.

FIGS. 7 and 8 show an exploded view and a mated view, respectively, ofan alternative embodiment of a connector 1000 having an alternativesecondary locking mechanism. Connector 1000 includes an upper housing1200, a lower housing 1300 and a lock plate 1335. Upper and lowerhousings 1200, 1300 include upper and lower terminal cavities 1221,1331, respectively. Upper and lower cavities 1221, 1331 includeterminals 40 (not shown). Lock plate 1335 includes upper protrusions1339.

Upper housing 1200 includes upper tabs 1220 (a similarly configuredmating tab as shown in FIG. 7 is present, but not shown, on the oppositeside of the housing 1200). Lower housing 1300 includes lower tabs 1320.Upper housing 1200 additionally includes tab recesses 1230 (a similarlyconfigured tab recess as seen in FIG. 7 is present, but not shown, onthe opposite side of the housing 1200) for engaging corresponding lowertabs 1320. Additionally, lower housing 1300 additionally includes lowertab recesses 1330 (a similarly configured lower tab recess as seen inFIG. 7 is present, but not shown, on the opposite side of the housing1300) for engaging corresponding upper tabs 1220. Connector 1000 has afront side 1012 and a rear side 1014.

FIG. 8 shows the connector 1000 of FIG. 7 having the upper and lowerhousings 1200, 1300 mated. As can be seen in FIG. 8, the upper and lowertabs 1220, 1320 engage corresponding tab recesses 1330, 1230 (tabs andrecesses on the opposite side not shown) to mate and form the assembledconnector 1000.

A sectional view of the exploded view of connector 1000 taken along lineB-B of FIG. 7 is shown in FIG. 9. As can be seen in FIG. 9, primaryterminal assurance is provided to terminals 40 in the upper housing 1200by upper housing lances 1224. Primary terminal assurance is provided toterminals 40 in the lower housing 1300 by lower housing lances 1334. Thelances 1224, 1334 protrude into their respective cavities 1221, 1331behind the front leading sections 42 of terminals 40 to prevent theterminals 40 from being moved towards the rear side 1014 of connector1000. Lances 1224, 1334 are integrally formed with their respectivehousings 1200, 1300 as shown in FIG. 9.

The secondary terminal assurance system includes lock plate 1335. Thelock plate 1335 is shown fully inserted into the lower housing 1300 inFIG. 9 to provide secondary terminal assurance to terminals 40 locatedin the lower housing 1300. When the lock plate 1335 is fully inserted,lower protrusions 1336 prevent the terminals 40 located in the lowerhousing 1300 from being withdraw from the lower cavities 1331 byengaging the lower rear edges 44 of terminals 40 when the terminals 40are pushed towards the rear 1014 of the connector 1000. The lock plate1335 includes tabs (not shown) for snap fitting the lock plate 1335 intothe lower housing 1300. In this exemplary embodiment, the lock plate1335 fits flushly into an opening 1305 in the lower surface 1310 of thelower housing 1300 as shown in FIG. 9. In alternative embodiments, thelock plate may protrude from the bottom surface 1310 of the lowerhousing 1300 and may include tabs or other structures to assist in theinsertion or removal of the lock plate 1335 into the lower housing 1300.

As can be further seen in FIG. 9, when upper and lower housings 1200,1300 are mated, the upper protrusions 1339 will be received in opening1226 in the upper housing 1200 and provide secondary terminal assuranceto the terminals 40 located in the upper housing 1200. Upper protrusions1339 will also prevent the mating of the upper and lower housings 1200,1300 if a terminal is not fully inserted into a cavity 1221 of the upperhousing 1200 by contacting the terminal 40 and not allowing theprotrusion 1339 from being fully received in the opening 1226. Thesecondary terminal assurance thus provides a check to the proper loadingof the loaded terminals 40 in the upper housing. Similarly, the plate1335 cannot be fully inserted and locked into the lower housing 1300 ifone of the terminals 40 is not fully inserted into a cavity 1331 of thelower housing 1300. The secondary terminal assurance provided toterminals 40 in the lower housing 1300 by protrusions 1336 engaging theterminals 40 thus provides a check to the proper terminal loading in thelower housing 1300. The protrusions 1336, 1339 are shown having a wedgegeometry, but other geometries including block shape, may be used toengage terminals 40.

Lock plate 1335 is completely detachable from the lower housing 1300when no terminals 40 are present in the lower housing 1300. The lockplate 1335 is detached by withdrawing the lock plate 1335 from thebottom surface 1310 of the lower housing 1300. As can be seen in FIG. 9,if terminals 40 are present in the lower housing 1300, those terminals40 will block the path of the upper protrusions 1339 when beingwithdrawn towards the opening 1305 in the bottom surface 1310 of thelower housing 1300. Thus, if any terminals 40 are present in the lowerhousing 1300, the lock plate 1335 cannot be withdrawn from the bottomsurface 1310 of the lower housing 1300.

FIG. 10 shows a cross sectional view of the assembled connector 1000 ofFIG. 9 taken along line B′-B′. As can be seen in FIG. 10, secondaryterminal assurance is provided to the terminals 40 located in the upperhousing 1200 by the secondary locking mechanism, which is provided byupper protrusions 1339 of lock plate 1335. As can be seen in FIG. 9,when the lock plate 1335 is fully inserted, upper protrusions 1339prevent the terminals 40 located in the upper housing 1200 from beingwithdrawn from the upper cavities 1221 by engaging the lower rear edges44 of terminals 40 when the terminals 40 are pushed towards the rear1014 of the connector 1000.

As can further be seen in FIG. 10, when upper and lower housings 1200,1300 are mated and the lock plate 1335 is fully inserted, theprotrusions 1336, 1339 of the lock plate 1335 prevent terminals 40 frombeing loaded into either or both the upper and lower housings 1200,1300, respectively.

An exemplary embodiment of loading of the terminals 40 into the upperand lower housings 1200, 1300 of connector 1000 is discussed referringto FIGS. 11 and 12. As can be seen in FIG. 11, the terminals 40 areloaded into the lower housing 1300 with the lock plate 1335 in apre-staged position and with the upper and lower housings 1200, 1300unmated. When the lock plate 1335 is in the pre-staged position, thelower protrusions 1336 are substantially flush with the cavities 1331 asshown, allowing the terminals 40 to be loaded into the cavities 1331.

The terminals 40 are loaded or inserted into the upper cavities 1221from the rear surface 1014 of the connector 1000 as shown. To be fullyinserted, the terminals 40 are inserted into the cavities 1221 until thefront leading sections 42 of the terminals 40 push passed lances 1224and the lances 1224 drop behind the leading sections 42. The lances 1224are sufficiently compliant to allow the front leading sections 42 topass. The terminals 40 are prevented from further forward movement byhousing cavity front sections 1360. The front leading sections 42 areallowed to float, or have a predetermined minimal movement, between thelances 1224 and the front sections 1360.

The terminals 40 are loaded into the lower housing 1300 prior to thelock plate 1335 being locked into the lower housing 1300. If the lockplate 1335 is locked into the lower housing 1300 prior to the terminals40 being received in the lower housing 1300, the protrusions 1336 willprevent the terminals 40 from being fully received in the lower housing1300. Additionally, the terminals 40 must be fully inserted in the lowerhousing 1300 before the lock plate 1336 can be locked into the lowerhousing 1300. If a terminal is not fully inserted into the lower housing1300, for example by being only partially inserted, the protrusions 1336will improperly contact the partially received terminal 40 and preventthe lock plate 1335 from locking into the lower housing 1300. Thisfeature provides a check of correct loading of all terminals 40 in thelower housing 1300. The lock plate 1335 may then be locked into thelower housing 1300 to secure the terminals 40 within the lower housing1300, for example, prior to shipment for assembly with the upper housing1200.

The lances 1334 provide primary terminal assurance by preventing theterminals 40 from being withdrawn from the cavities 1331. The lances1334 engage the leading sections 42 when the terminals 40 are pushedtowards the rear 1014 of the connector 1000 and prevent the terminals 40from any further rearward movement. The housing cavity front sections1360 prevent the terminals 40 from further forward movement towards thefront side 1212 of the connector 1000.

The terminals 40 are loaded into the upper housing 1200 either prior tothe lower housing 1300 with locked lock plate 1335 being mated thereto,or after mating with the lower housing 1300 but before the lock plate1335 is locked into the lower housing 1300. The terminals 40 must befully inserted in the upper housing 1200 before the wedges 1339 areinserted into the opening 1226 (FIG. 9) in the upper housing 1200. Theterminals are received into the upper cavities 1221 from the rear side1014 of the connector 1000. To be fully inserted, the terminals 40 areinserted into the cavities 1221 until the front leading sections 42 ofthe terminals 40 push passed lances 1224 and the lances 1224 drop behindthe leading sections 42. The lances 1224 are sufficiently compliant toallow the front leading sections 42 to pass. The terminals 40 areprevented from further forward movement by housing cavity front sections1260. The front leading sections 42 are allowed to float, or have apredetermined minimal movement, between the lances 1224 and the frontsections 1260.

The lances 1224 provide primary terminal assurance by preventing theterminals 40 from being withdrawn from the cavities 1231. The lances1224 engage the leading sections 42 when the terminals 40 are pushedtowards the rear 1014 of the connector 1000 and prevent the terminals 40from any further rearward movement. The housing cavity front sections1260 prevent the terminal.

FIG. 12 shows a sectional view of FIG. 11 with the terminals 40 fullyinserted and the upper and lower housings 1200, 1300 mated. The lockplate 1335 is shown in a pre-staged position. The lock plate 1335 hasprotrusions (not shown) that engage recesses (not shown) in the lowerhousing 1300 that temporarily lock the lock plate 1335 into thepre-staged position. As can be seen in FIG. 12, the loaded terminals 40in the upper and lower housings 1200, 1300 are secured by primaryterminal assurance provided by the upper and lower lances 1224, 1334,respectively. In this pre-staged position, additional terminals 40 maystill be loaded into unloaded upper or lower cavities 1221, 1321.Additionally, terminals 40 may be removed from the upper and lowercavities 1221, 1321 with the aid of a tool (not shown) that can beinserted into the cavities 1221, 1321 from the rear side 1014, whichdisengages the lances 1224, 1334 from the terminals 40 and allows theterminals 40 to be removed. After all terminals 40 have been fullyinserted into the upper and lower housings 1200, 1300, the lock plate1335 is fully inserted and secured into the lower housing 1300 toprovide secondary terminal assurance to the terminals 40. The secondaryterminal assurance is provided by the upper and lower protrusions 1339,1336 of the locking plate 1335 that prohibit the terminals 40 from beingmoved towards the rear side 1014 of the connector 1000 as shown in FIG.10. The lock plate 1335 includes tabs or protrusions (not shown) thatengage recesses or surfaces (not shown) in or on the lower housing 1300to secure the lock plate 1335 into a fully inserted position.

The terminals of the disclosed embodiments may be formed of a highlyconductive metal or alloy or other known industry acceptable terminal orcontact material. The upper and lower housings of the disclosedembodiments may be formed of known industry acceptable non-conductivepolymers.

While the invention has been described with reference to a preferredembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiment disclosed as the best modecontemplated for carrying out this invention, but that the inventionwill include all embodiments falling within the scope of the appendedclaims.

1. An electrical connector, comprising: an upper housing comprisingcavities configured to receive electrical terminals and upper housinglances integrally formed into the upper housing for providing primaryterminal assurance to the terminals received in the cavities in theupper housing; a lower housing configured to be mated to the upperhousing to form the electrical connector, the lower housing comprisingcavities configured to receive electrical terminals and lower housinglances integrally formed into the lower housing for providing primaryterminal assurance to terminals received in the lower housing; and asecondary terminal assurance system configured to provide secondaryterminal assurance to terminals received in the lower housing; whereinthe secondary terminal assurance system comprises a lock plate.
 2. Theconnector of claim 1, wherein the lock plate comprises a plurality offirst protrusions that provide the secondary terminal assurance toterminals received in the lower housing when the lock plate is insertedinto the lower housing.
 3. The connector of claim 1, wherein the lockplate comprises a plurality of second protrusions that provide secondaryterminal assurance to terminals received in the upper housing when thelock plate is inserted into the lower housing and the lower housing andupper housing are mated.
 4. The connector of claim 1, wherein the lockplate comprises tabs that secure the lock plate into the lower housingwhen fully inserted.
 5. The connector of claim 1, wherein the lock plateprevents mating the upper housing to the lower housing if a terminal isnot fully inserted in the upper housing.
 6. The connector of claim 1,wherein the lock plate is detachable from the lower housing.
 7. Theconnector of claim 1, wherein the lock plate is attached to the lowerhousing.
 8. The connector of claim 1, wherein the lock plate isprevented from being removed from the lower housing when terminals areinserted into the lower housing.
 9. The connector of claim 1, whereinthe upper lances and the lower lances secure terminals received in theupper housing and the lower housings, respectively, from moving.
 10. Theconnector of claim 8, wherein the lock plate is configured so terminalscan be loaded into the cavities of the upper housing and the lowerhousing when the lock plate is partially inserted into the lowerhousing.
 11. A method of assembling an electrical connector comprising:providing an upper housing comprising cavities configured to receive andsecure electrical terminals and upper housing lances configured toprovide primary terminal assurance to the terminals received in thecavities in the upper housing; providing a lower housing configured tomate with the upper housing to form the electrical connector, the lowerhousing comprising cavities configured to receive and secure electricalterminals and lower housing lances configured to provide primaryterminal assurance to terminals received in the lower housing; providinga secondary terminal assurance system configured to provide secondaryterminal assurance to terminals received in the upper and lowerhousings; and mating the upper and lower housings to form the electricalconnector; wherein the secondary terminal assurance system is a lockplate.
 12. The method of claim 10, wherein the lock plate comprises aplurality of first protrusions that provide the secondary terminalassurance to terminals received in the lower housing when the lock plateis inserted into the lower housing.
 13. The method of claim 10, whereinthe lock plate comprises a plurality of second protrusions that providesecondary terminal assurance to terminals received in the upper housingwhen the lock plate is inserted into the lower housing and the lowerhousing and upper housing are mated.
 14. The method of claim 10, whereinthe lock plate comprises tabs that secure the lock plate into the lowerhousing when fully inserted.
 15. The method of claim 10, wherein thelock plate prevents mating the upper housing to the lower housing if aterminal is not fully inserted in the upper housing.
 16. The method ofclaim 10, wherein the lock plate is detachable from the lower housing.17. The method of claim 10, wherein the lock plate is prevented frombeing removed from the lower housing when terminals are inserted intothe lower housing.
 18. The method of claim 10, wherein the upper lancesand the lower lances secure terminals received in the upper housing andthe lower housings, respectively, from moving.
 19. The method of claim10, wherein the lock plate is configured so terminals can be loaded intothe cavities of the upper housing and the lower housing when the lockplate is partially inserted into the lower housing.